U.S. patent number 5,399,219 [Application Number 08/200,593] was granted by the patent office on 1995-03-21 for method for making a fastening system for a dynamic fitting diaper.
This patent grant is currently assigned to Kimberly-Clark Corporation. Invention is credited to Kathleen A. O'Rourke, Thomas H. Roessler, Paul T. Van Gompel.
United States Patent |
5,399,219 |
Roessler , et al. |
March 21, 1995 |
Method for making a fastening system for a dynamic fitting
diaper
Abstract
A method for forming a plurality of adhesive fastener assemblies
includes the step of providing a substantially continuous web of
substrate material along a selected, longitudinal machine-direction
(132). The substrate web has a laterally extending cross direction
(134) which is substantially perpendicular to the machine
direction, and has laterally opposed, longitudinally extending side
edge regions (142 and 144) thereof. A selected fastening means,
such as a layer of primary adhesive (54), is positioned and applied
onto a major facing surface (186) of the substrate web (140). A
first longitudinally extending web of stiffening material (154) is
attached to the major surface of the substrate web (140) at a
location which is proximate a first side edge region (142) of the
substrate web. A second longitudinally extending web of stiffening
material (156) is attached to the major surface of the substrate
web (140) at a location which is proximate the second side edge
region (144) of the substrate web (140). The web of substrate
material and the webs of stiffening material thereby form a
substrate composite (192). The substrate web is separated along a
longitudinally extending medial region thereof, with a
substantially regularly undulating serpentine separation line (158)
to provide an opposed pair of fastener tab subassemblies (194 and
196).
Inventors: |
Roessler; Thomas H. (Menasha,
WI), Van Gompel; Paul T. (Hortonville, WI), O'Rourke;
Kathleen A. (Neenah, WI) |
Assignee: |
Kimberly-Clark Corporation
(Neenah, WI)
|
Family
ID: |
22742364 |
Appl.
No.: |
08/200,593 |
Filed: |
February 23, 1994 |
Current U.S.
Class: |
156/259; 156/229;
604/391; 156/269; 156/324; 604/389; 604/390; 156/271; 156/265 |
Current CPC
Class: |
B31D
1/0062 (20130101); A61F 13/622 (20130101); A61F
13/15756 (20130101); A61F 13/58 (20130101); Y10T
156/1077 (20150115); Y10T 156/1087 (20150115); Y10T
156/1067 (20150115); Y10T 156/1084 (20150115) |
Current International
Class: |
A61F
13/56 (20060101); A61F 13/58 (20060101); A61F
13/15 (20060101); A61F 13/62 (20060101); B31D
1/00 (20060101); A61F 013/60 (); A61F 013/58 ();
B32B 031/18 () |
Field of
Search: |
;156/229,259,264,265,269,271,324,289 ;604/389,390,391 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
0110010A1 |
|
Jun 1984 |
|
EP |
|
0191355A1 |
|
Aug 1986 |
|
EP |
|
0233704B1 |
|
Aug 1987 |
|
EP |
|
0396050A2 |
|
Nov 1990 |
|
EP |
|
0433951A2 |
|
Jun 1991 |
|
EP |
|
0463276A1 |
|
Jan 1992 |
|
EP |
|
0487758A1 |
|
Jun 1992 |
|
EP |
|
0532034A2 |
|
Mar 1993 |
|
EP |
|
0539032A1 |
|
Apr 1993 |
|
EP |
|
1359810 |
|
Mar 1963 |
|
FR |
|
2403036 |
|
Apr 1979 |
|
FR |
|
2606257 |
|
May 1988 |
|
FR |
|
3419621A1 |
|
Nov 1985 |
|
DE |
|
3419623A1 |
|
Nov 1985 |
|
DE |
|
069653 |
|
Apr 1986 |
|
IL |
|
5-65321 |
|
Aug 1993 |
|
JP |
|
6-11725 U |
|
Feb 1994 |
|
JP |
|
450816 |
|
Jul 1936 |
|
GB |
|
808966 |
|
Feb 1959 |
|
GB |
|
1379689 |
|
Jan 1975 |
|
GB |
|
2244422A |
|
Dec 1991 |
|
GB |
|
2257895A |
|
Jan 1993 |
|
GB |
|
WO90/07426 |
|
Jul 1990 |
|
WO |
|
WO91/00720 |
|
Jan 1991 |
|
WO |
|
Primary Examiner: Aftergut; Jeff H.
Attorney, Agent or Firm: Yee; Paul
Claims
We claim:
1. A method for forming a plurality of adhesive fastener
assemblies, comprising the steps of:
(a) providing a web of substrate material along a longitudinal
direction, said substrate web having a major facing surface thereof
and having first and second side edge regions thereof;
(b) providing for a component of a primary fastening means disposed
across said major surface of said substrate;
(c) attaching a first web of stiffening material to said substrate
web at a location Which is proximate said first side edge region of
said substrate web;
(d) attaching a second web of stiffening material to said substrate
web at a location which is proximate said second side edge region
of said substrate web; and
(e) separating a medial region of said substrate web along a
generally longitudinally extending serpentine line which extends
into said first and second webs of stiffening material to provide
at least first and second fastener tab subassemblies.
2. A method as recited in claim 1, further comprising the step of
dividing at least one of said first and second fastener tab
subassemblies to provide a plurality of fastening tabs.
3. A method as recited in claim 1, further comprising the steps
of:
(f) attaching a first web of side panel material to an outboard
side region of said first fastener tab subassembly to form a first
composite panel-and-fastener subassembly; and
(g) attaching a second web of side panel material to an outboard
side region of said second fastener tab subassembly to form at
least a second composite panel-and-fastener subassembly.
4. A method as recited in claim 3, wherein said attaching step (f)
is configured to provide a first web of side panel material
composed of an elastomeric material which is stretchable along a
cross-direction of said first side panel web; and said attaching
step
(g) is configured to provide a second web of side panel material
composed of an elastomeric material which is stretchable along a
cross-direction of said second side panel web.
5. A method as recited in claim 4, further comprising the step of
dividing at least one of said first and second composite
subassemblies to provide a plurality of panel-and-fastener
components.
6. A method as recited in claim 5, wherein
said step (c) comprises the step of attaching a first web of
stiffening material composed of a first web of release material,
said first release web having a first securement surface and having
a release surface thereof which is located opposite said securement
surface, said release surface constructed to releasably adhere to
said component of said primary fastening means; and
said step (d) comprises the step of attaching a second web of
stiffening material composed of a second web of release material,
said second release web having a second securement surface and
having a second release surface thereof which is located opposite
said second securement surface, said second release surface
constructed to releasably adhere to said component of said primary
fastening means.
7. A method as recited in claim 5, further comprising the step of
connecting at least one of said panel-and-fastener assemblies to
each of a pair of lateral side regions of a waistband portion of an
article.
8. A method as recited in claim 7, wherein said separating step (e)
is configured to separate said composite along a serpentine line
having traversing sections which extend into a portion of each of
said release webs.
9. A method as recited in claim 8, wherein said traversing sections
of said serpentine line include retroceding portions thereof.
10. A method as recited in claim 1, wherein said providing step (b)
includes the step of providing a fastening means which includes a
layer of adhesive disposed on said major surface of said web of
substrate material.
11. A method as recited in claim 1, wherein said providing step (b)
includes the step of having disposed a fastening means comprising a
cooperative component of an interlocking mechanical fastener on
said major surface of said web of substrate material.
12. A method as recited in claim 11, wherein said disposing step
(b) includes the step of having disposed a cooperative hook
component of a hook-and-loop type mechanical fastener system on
said major surface of said web of substrate material.
13. A method for forming a plurality of stretch panel fasteners,
comprising the steps of:
(a) providing a first, substantially continuous web of
elastomerically stretchable material extending along a selected,
longitudinal machine-direction, said material being elastomerically
stretchable at least along a laterally extending cross-direction
which is substantially perpendicular to said machine-direction;
(b) providing at least a second, substantially continuous web of
elastomerically stretchable material extending along said
machine-direction, said material being elastomerically stretchable
at least along said cross-direction;
(c) spacing said second web of stretchable material from said first
web of stretchable material by a selected distance along said
cross-direction;
(d) providing a substantially continuous web of substrate material
along said machine-direction at a location which is between said
first and second webs of stretchable material, said substrate web
having laterally opposed, longitudinally extending side edge
regions thereof;
(e) attaching a longitudinally extending lateral side edge region
of said first web of stretchable material to said first, side edge
region of said substrate web to provide a first bonded region;
(f) attaching a longitudinally extending lateral side edge region
of said second web of stretchable material to said second, side
edge region of said substrate web to provide a second bonded
region;
(g) laying a first longitudinally extending web of stiffening
material at a position proximate said first bonded region, and
connecting said first stiffening web to at least said first web of
stretchable material;
(h) laying a second longitudinally extending web of stiffening
material at a position proximate said second bonded region, and
connecting said second stiffening web to at least said second web
of stretchable material;
(i) separating said substrate web along a longitudinally extending
medial region thereof with a substantially regularly undulating
serpentine separation line to provide an opposed pair of composite
subassemblies;
(j) dividing at least one subassembly along a plurality of division
lines which extend substantially laterally across said subassembly
to provide a plurality of combined panel-and-fastener
components.
14. A method as recited in claim 13, wherein said separating step
(e) includes the step of separating said substrate web along said
longitudinally extending medial region with a substantially
regularly undulating serpentine line having alternating,
longitudinally retroceding portions thereof.
15. A method as recited in claim 14, wherein said dividing step (j)
includes the step of dividing at least one subassembly along a
plurality of division lines which extend substantially laterally
across said subassembly to provide a plurality of longitudinally
paired, combined panel-and-fastener components.
16. A method as recited in claim 15, further comprising the steps
of:
(k) of securing at least one of said longitudinally paired
panel-and-fastener components to each of two laterally opposed end
regions of an appointed waistband section of an article web to
provide composite article web; and
(l) severing said composite article web along a cross-direction
thereof at a location which divides each of said longitudinally
paired panel-and-fastener components into two individual
panel-and-fastener components.
17. A method as recited in claim 13, wherein
said laying step (g) includes the step of overlapping said first
longitudinally extending web of stiffening material over said first
bonded region, and connecting said first stiffening web to said
first web of stretchable material and to said substrate web;
and
said laying step (h) includes the step of overlapping said second
longitudinally extending web of stiffening material over said
second bonded region, and connecting said second stiffening web to
said second web of stretchable material and to said substrate
web.
18. A method as recited in claim 17, wherein said dividing step (j)
includes the step of dividing at least one subassembly along a
plurality of division lines which extend substantially laterally
across said subassembly to provide a plurality of longitudinally
paired, combined panel-and-fastener components.
19. A method as recited in claim 18, further comprising the steps
of:
(k) of securing at least one of said longitudinally paired
panel-and-fastener components to each of two opposed end regions of
an appointed waistband section of an article web to provide a
composite article web; and
(l) severing said composite article web along a cross-direction
thereof at a location which divides each of said longitudinally
paired panel-and-fastener components into two individual
panel-and-fastener components.
20. A method for forming a plurality of stretch panel fasteners,
comprising the steps of:
(a) providing a first, substantially continuous web of
elastomerically stretchable material extending along a selected,
longitudinal machine-direction, said material being elastomerically
stretchable at least along a laterally extending cross-direction
which is substantially perpendicular to said machine-direction;
(b) providing at least a second, substantially continuous web of
elastomerically stretchable material extending along said
machine-direction, said material being elastomerically stretchable
at least along said cross-direction;
(c) spacing said second web of stretchable material from said first
web of stretchable material by a selected distance along said
cross-direction;
(d) providing a substantially continuous web of substrate material
along said machine-direction at a location which is between said
first and second webs of stretchable material, said substrate web
having laterally opposed, longitudinally extending side edge
regions thereof;
(e) attaching a longitudinally extending lateral side edge region
of said first web of stretchable material to said first, side edge
region of said substrate web to provide a first bonded region;
(f) attaching a longitudinally extending lateral side edge region
of said second web of stretchable material to said second, side
edge region of said substrate web to provide a second bonded
region;
(g) laying a first longitudinally extending web of stiffening
material at a position proximate said first bonded region, and
connecting said first stiffening web to at least said first web
stretchable material;
(h) laying a second longitudinally extending web of stiffening
material at a position proximate said second bonded region, and
connecting said second stiffening web to at least said second web
of stretchable material;
(i) placing a web of release tape material onto said substrate
web;
(j) separating said substrate web and said release tape web along a
longitudinally extending medial region thereof with a substantially
regularly undulating serpentine separation line to provide an
opposed pair of composite subassemblies;
(k) dividing at least one subassembly along a plurality of division
lines which extend substantially laterally across said subassembly
to provide a plurality of combined panel-and-fastener
components;
(l) securing at least one of said panel-and-fastener components to
each of two laterally opposed end regions of an appointed waistband
section of an article web to provide composite article web;
(m) inwardly folding said first and second webs of elastomerically
stretchable material to anchor said release tape material onto a
selected surface of said article web.
21. A method as recited in claim 20, wherein said separating step
(j) includes the step of separating said substrate web along said
longitudinally extending medial region with a substantially
regularly undulating serpentine line having alternating,
longitudinally retroceding portions thereof.
22. A method as recited in claim 21, wherein
said dividing step (k) includes the step of dividing at least one
subassembly along a plurality of division lines which extend
substantially laterally across said subassembly to provide a
plurality of longitudinally paired, combined panel-and-fastener
components,
said securing step (l) includes the step of securing at least one
of said longitudinally paired panel-and-fastener components to each
of two, laterally opposed end regions of said waistband section of
said article web to provide said composite article web; and
further comprising the step of severing said composite article web
along a cross-direction thereof at a location which divides each of
said longitudinally paired panel-and-fastener components into two
individual panel-and-fastener components.
Description
FIELD OF THE INVENTION
The present invention relates to fastening systems for disposable
garments, such as caps, gowns, diapers, shoe covers, incontinence
garments and the like. More particularly, the present invention
relates to adhesive tape fastening systems and interlocking,
mechanical-type fastening systems for disposable articles, such as
gowns, diapers, incontinence garments and the like.
BACKGROUND OF THE INVENTION
Conventional disposable absorbent articles have typically employed
adhesive fastening tapes for securing the article on a wearer. For
example, see U.S. Pat. No. 2,714,889 issued Aug. 9, 1955, to U.
Chambers and U.S. Pat. No. 4,050,462 issued Sep. 27, 1977, to L.
Woon et al. Conventional adhesive tape fastening systems have
employed adhesive tape tabs which include a non-adhesive section
located at the distal free end of the tape tab. This adhesive-free
region has typically referred to as a finger tab for facilitating
the grasping of the end of the adhesive tape. For example, U.S.
Pat. No. 4,055,182 issued Oct. 25, 1977, to R. Mack describes an
end tab formed by folding the end region of the tab back onto
itself. Other adhesive tape structures have included a finger tab
formed by placing a separate piece of material at the terminal free
end of the tape member. For example, see U.S. Pat. No. 4,726,971
issued Feb. 23, 1988, to P. Pape et al.; U.S. Pat. No. 3,616,114
issued Oct. 26, 1971, to T. Hamaguchi et al.; U.S. Pat. No.
4,801,480 issued Jan. 31, 1989, to V. Panza et al. Other articles
have included a fastening system which extends along substantially
the entire length of an ear section of the article. Still other
conventional fastening systems have employed tapered fastening tabs
where the user's end is relatively wide at the longitudinally
extending sides of the diaper, and is tapered to a more narrow
width at its distal end. For example, see European Patent 0 233 704
B1 of H. Burkhard et al.
Conventional fastening systems, such as those described above, have
not provided an adequate level of dynamic fit in combination with a
neat tailored appearance and reliable securement. Processes for
producing such conventional fastening systems have not been
adequate for producing improved fastening systems that have a
greater capability of moving and adjusting to accommodate the
stresses and displacements caused by an active wearer. As a result,
the conventional methods have not been adequate for producing
fastening systems which are configured to exhibit desired levels of
reliable securement and comfort.
BRIEF DESCRIPTION OF THE INVENTION
Generally stated, a distinctive method for forming a plurality of
fastener assemblies includes the step of providing a substantially
continuous web of substrate material along a selected, longitudinal
direction. The substrate web has a major facing surface thereof,
and has first and second side edge regions thereof. A selected
fastening means is provided for on the major facing surface of the
substrate web. A first web of stiffening material is attached to
the substrate web at a location which is proximate the first side
edge region of the substrate web. A second web of stiffening
material is attached to the substrate at a location which is
proximate the second side edge region of the substrate web. A
medial region of the substrate web is separated along an undulating
serpentine separation line to provide at least first and second
fastener tab subassemblies. In particular configurations, either or
both webs of side panel material are constructed of an elastomeric
material which is stretchable at least along a cross-deckle
direction of the method.
A further process aspect of the invention provided a method for
forming a plurality of adhesive fastener assemblies, which includes
the step of providing a substantially continuous web of substrate
material along a selected, longitudinal machine-direction. The
substrate web has a laterally extending cross-direction which is
substantially perpendicular to said machine-direction, and has
laterally opposed, longitudinally extending side edge regions. A
component of a primary fastening means is provided on a major
facing surface of the substrate web. A first longitudinally
extending web of stiffening material is attached to the substrate
web at a location which is proximate a first of the substrate side
edge regions, and a second longitudinally extending web of
stiffening material is attached to the substrate web at a location
which is proximate a second of the substrate side edge regions. The
substrate web is separated along a longitudinally extending medial
region thereof with a substantially regularly undulating serpentine
separation line to provide for an opposed pair of fastener tab
subassemblies. At least one of the fastener tab subassemblies is
divided along a plurality of division lines which extend
substantially laterally across the at least one subassembly to
provide a plurality of fastener tab components having an appointed
factory bond region thereof. The factory bond regions of a
plurality of said fastener tab components are connected to at least
one longitudinally extending side edge region of a substantially
continuous web of elastomerically stretchable material which is
elastomerically stretchable at least along the cross-direction. The
elastomerically stretchable web is severed along a plurality of
severance lines which extend substantially laterally across the
stretchable web to provide for a plurality of composite
panel-and-fastener components.
Still another process aspect of the invention provides a method for
forming an article having stretch panel fasteners, which includes
the step of providing a first, substantially continuous web of
elastomerically stretchable material along a selected, longitudinal
machine-direction. The material is elastomerically stretchable at
least along a laterally extending cross-direction which is
substantially perpendicular to the machine-direction. At least a
second, substantially continuous web of the elastomerically
stretchable material is provided along the machine-direction, and
the second web of stretchable material is spaced from the first web
of stretchable material by a selected distance along the cross
direction. A substantially continuous web of substrate material is
provided along the machine-direction at a location which is between
the first and second webs of stretchable material. The substrate
web has laterally opposed, longitudinally extending side edge
regions thereof. A longitudinally extending lateral side edge
region of the first web of stretchable material is attached to the
first, side edge region of the substrate web to provide a first
bonded region. A longitudinally extending lateral side edge region
of the second web of stretchable material is attached to the
second, side edge region of the substrate web to provide a second
bonded region. A first longitudinally extending web of stiffening
material is overlapped over the first bonded region and the first
stiffening web is connected to the first web of stretchable
material and to the substrate web. A second longitudinally
extending web of stiffening material is overlapped over the second
bonded region and the second stiffening web is connected to the
second web of stretchable material and to the substrate web. The
substrate web is separated along a longitudinally extending medial
region thereof with a substantially regularly undulating serpentine
separation line to provide an opposed pair of composite
subassemblies. At least one subassembly is divided along a
plurality of division lines which extend substantially laterally
across the subassembly to provide a plurality of longitudinally
paired, combined panel-and-fastener components.
The various process aspects of the present invention can
advantageously provide an efficient technique for rapidly producing
the taping system of the invention. In particular configurations,
the method can be carried out in-line with the process for
manufacturing the associated article that employs the tape
fastening system, thereby helping to reduce costs.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood and further
advantages will become apparent when reference is made to the
following detailed description of the invention and the drawings,
in which:
FIG. 1 representatively shows a top plan view of an article and
fastening system which can be produced with the method of the
present invention;
FIG. 2 representatively shows a top plan view of a fastening system
having a panel-and-fastener component which can be produced with
the method of the present invention;
FIG. 3 representatively shows a cross-sectional view of the
fastening system illustrated in FIG. 2;
FIG. 4 representatively shows a top plan view of a process for
forming a composite web which can be divided into individual
fastener tabs;
FIGS. 4A and 4B representatively shows a top plan view of an
opposed pair of fastener tab subassemblies formed from the
composite web illustrated in FIG. 4;
FIG. 4C representatively shows a top plan view of a fastener tab
formed from one of the fastener tab subassemblies illustrated in
FIG. 4;
FIG. 5 representatively shows a top plan view of a process for
forming a composite web which can be divided into individual
fastener tabs, wherein webs of stiffening material are composed of
a release tape material;
FIG. 5A representatively shows a cross-sectional view of the
process configuration illustrated in FIG. 5;
FIG. 6 representatively shows a top plan view of a process for
forming a composite web which can be divided into individual
panel-and-fastener components;
FIG. 6A representatively shows a cross-sectional view of the
process illustrated in FIG. 6;
FIG. 7 representatively shows an alternative method for producing a
composite web which can be divided into individual
panel-and-fastener components;
FIG. 8 representatively shows a top plan view of an aspect of the
invention which includes the step of forming longitudinally-paired
fastener tab sets;
FIG. 9 representatively shows a top plan view of an aspect of the
invention which is configured to form a selected plurality of
longitudinally-paired, panel-and-fastener components;
FIG. 10 representatively shows another alternative method for
producing a composite web which can be divided into individual
panel-and-fastener components;
FIG. 11 representatively shows a top plan view of an aspect of the
invention which includes the step of connecting
longitudinally-paired fastener tab sets to appointed waistband
sections of an article web;
FIG. 12 representatively shows a top plan view of an aspect of the
invention which includes the step of disposing a web of release
tape material onto an adhesive-bearing surface of a substrate
web;
FIG. 12A representatively shows a top plan view of a
panel-and-fastener subassembly formed from the method illustrated
in FIG. 12;
FIG. 12B representatively shows a top plan view of a
panel-and-fastener component formed from the subassembly
illustrated in FIG. 12A;
FIG. 12C representatively shows a top plan view of the
panel-and-fastener component illustrated in FIG. 12B where the
fastener tab has been folded over into its storage
configuration;
FIG. 12D representatively shows a top plan view of the
panel-and-fastener component illustrated in FIG. 12C where the
fastener tab has been unfolded from its storage configuration into
an arrangement ready for forming a desired user-bond;
FIG. 13 representatively shows a top plan view of another aspect of
the invention which includes the step of disposing a web of release
tape material onto an adhesive-bearing surface of a substrate
web;
FIG. 13A representatively shows a top plan view of a further aspect
of the invention which includes the step of disposing a narrower
web of release tape material onto an adhesive-bearing surface of a
substrate web;
FIG. 13B representatively shows a top plan view of a
panel-and-fastener subassembly formed from the method illustrated
in FIG. 13A;
FIG. 13C representatively shows a top plan view of a
panel-and-fastener component formed from the subassembly
illustrated in FIG. 13B;
FIG. 13D representatively shows a top plan view of the
panel-and-fastener component illustrated in FIG. 13C where the
fastener tab has been folded over into its storage
configuration;
FIG. 13E representatively shows a top plan view of the
panel-and-fastener component illustrated in FIG. 13D where the
fastener tab has been unfolded from its storage configuration into
an arrangement ready for forming a desired user-bond;
FIG. 14 representatively shows a partial, top plan view of a
composite article web wherein a release tape tab is anchored to an
inner surface of a topsheet layer of the article web, and wherein
the fastener tab has been moved from its storage position on the
release tape to a position ready for producing the desired
user-bond;
FIG. 14A representatively shows a schematic side elevational view
of the composite article web illustrated in FIG. 14;
FIG. 15 representatively shows a top plan view of an aspect of the
invention which includes the steps of connecting first and second
longitudinally extending webs of stiffening material to a major
facing surface of a substrate web at locations which are proximate
first and second side edge regions of the substrate web, and are
laterally, inwardly spaced from each of the corresponding first and
second side edge regions of the substrate web; and
FIG. 16 representatively shows a top plan view of an aspect of the
invention which includes the steps of attaching first and second
longitudinally extending webs of stiffening material to a major
facing surface of first and second elastomeric webs at selected
locations which laterally, outwardly spaced from the side edge
regions of a medially positioned substrate web.
DETAILED DESCRIPTION OF THE INVENTION
The various embodiments of the invention will be described in the
context of a disposable absorbent article, such as a disposable
diaper. It is, however, readily apparent that the present invention
could also be employed with other articles, such as caps, gowns,
shoe covers, feminine care articles, incontinence garments and the
like.
Typically, disposable articles are intended for limited use and are
not intended to be laundered or otherwise cleaned for reuse. For
example, a disposable diaper is discarded after it has become
soiled by the wearer.
The method of the present invention can be employed to produce a
plurality of selected panel-and-fastener components for various
articles, such as a disposable diaper 20. With reference to FIGS. 1
and 2, the representative diaper 20 is shown in its fully extended
condition with all of the elasticized gathers stretched out and
removed. The article has a first waistband section, such as rear
waistband section 40, a second waistband section, such as front
waistband section 38, and an intermediate section 42 which
interconnects the first and second waistband sections. The article
comprises a backsheet layer 22, and a pair of side panels 90, each
of which extends laterally from opposed lateral ends of at least
one waistband section of backsheet 22. Each of the side panels
includes a terminal free end region 92 which has a predetermined
length dimension 94 thereof. Each side panel also has a width 91
and a base length 93. A stress beam section 98 is connected to each
of the side panels 90 along its free end region 92, and the stress
beam section provides for a relatively high Gurley stiffness value,
such as a Gurley stiffness value of at least about 20 mg. The
stress beam section also has a length dimension 102 which is at
least a significant substantial percentage, such as about 33
percent, of the length 94 of the free end region 92 of the side
panel. A fastening tab 44 is connected to each of the stress beam
sections and is arranged to extend laterally from each of the side
panels 90 for securing the waistband sections of the article about
a wearer during the use of the article. In particular
configurations of the invention, the fastening tab can have a base
length 58 which is not more than a selected limited percentage,
such as about 90 percent, of the length 102 of the stress beam
section 98.
The disposable diaper 20 has a first waistband section, such as
rear waistband section 40, a second waistband section, such as
front waistband section 38, and an intermediate section 42 which
interconnects the first and second waistband sections. The article
comprises a backsheet layer 22, and a fastening means, such as
fastening tab 44, operably connected to opposed lateral ends of at
least one waistband portion 40 or 38 of the backsheet layer for
securing the waistband sections of the article about a wearer
during the use of the article. The fastening means has a factory
bond section 50, a user bond section 52, and a seam section 69
which is located between the factory bond and user bond sections.
The user bond section has a length dimension, such as fastening tab
length 62, which is larger than a length dimension of said seam
section. Depending upon the particular tab configuration, the seam
section length may correspond to the base length 58 or the
intermediate length 66 of the fastening tab, as appropriate.
An aspect of the invention can provide a fastener article which
comprises a tab substrate 48 having a factory bond section 50, a
user bond section 52, and a seam section 69 which is located
between the factory bond and user bond sections. The user bond
section has a length dimension, such as fastening tab length 62,
which is larger than a length dimension of the seam section.
Depending upon the particular tab configuration, the seam section
length may correspond to the base length 58 or to the intermediate
length 66 of the fastener tab, as appropriate.
In the various configurations of the invention, diaper 20 can
further include a liquid permeable topsheet layer 24 superposed in
facing relation with the backsheet layer, and an absorbent body 26
interposed between the backsheet and topsheet layers.
Diaper 20 defines a longitudinally extending length dimension 86
and a laterally extending width dimension 88, as representatively
shown in FIG. 1, and may have any desired shape, such as
rectangular, I-shaped, a generally hourglass shape, or a T-shape.
With the T-shape, the crossbar of the "T" may comprise the front
waistband portion of the diaper or may alternatively comprise the
rear waistband portion of the diaper.
Backsheet 22 can generally provide an outer cover member of the
article and may be composed of a liquid permeable material, but
preferably comprises a material which is configured to be
substantially impermeable to liquids. For example, a typical
backsheet can be manufactured from a thin plastic film, or other
flexible liquid-impermeable material. As used in the present
specification, the term "flexible" refers to materials which are
compliant and which will readily conform to the general shape and
contours of the wearer's body. Backsheet 22 prevents the exudates
contained in absorbent body 26 from wetting articles, such as
bedsheets and overgarments, which contact diaper 20. In particular
embodiments of the invention, backsheet 22 is a polyethylene film
having a thickness of from about 0.012 millimeters (0.5 mil) to
about 0.051 millimeters (2.0 mils). In the shown embodiment, the
backsheet is a film having a thickness of about 1-1.5 mil. For
example, the backsheet film can have a thickness of about 1.25 mil.
Alternative constructions of the backsheet may comprise a woven or
nonwoven fibrous web layer which has been totally or partially
constructed or treated to impart the desired levels of liquid
impermeability to selected regions that are adjacent or proximate
the absorbent body. Backsheet 22 typically provides the outer cover
of the article. Optionally, however, the article may comprise a
separate outer cover member which is in addition to the
backsheet.
Backsheet 22 may alternatively be composed of a micro-porous,
"breathable" material which permits gases, such as water vapor, to
escape from absorbent body 26 while substantially preventing liquid
exudates from passing through the backsheet. For example, the
breathable backsheet may be composed of a microporous polymer film
or a nonwoven fabric which has been coated or otherwise treated to
impart a desired level of liquid impermeability. For example, a
suitable microporous film can be a PMP-1 material, which is
available from Mitsui Toatsu Chemicals, Inc., a company having
offices in Tokyo, Japan; or an XK0-8044 polyolefin film available
from 3M Company of Minneapolis, Minn. The backsheet may also be
embossed or otherwise be provided with a matte finish to exhibit a
more aesthetically pleasing appearance.
The size of backsheet 22 is typically determined by the size of
absorbent body 26 and the particular diaper design selected.
Backsheet 22, for example, may have a generally T-shape, a
generally I-shape or a modified hourglass shape, and may extend
beyond the terminal edges of absorbent body 26 by a selected
distance.
Topsheet 24 presents a body-facing surface which is compliant,
soft-feeling, and non-irritating to the wearer's skin. Further,
topsheet 24 can be less hydrophilic than absorbent body 26, and is
sufficiently porous to be liquid permeable, permitting liquid to
readily penetrate through its thickness to reach the absorbent
body. A suitable topsheet 24 may be manufactured from a wide
selection of web materials, such as porous foams, reticulated
foams, apertured plastic films, natural fibers (for example, wood
or cotton fibers), synthetic fibers (for example, polyester or
polypropylene fibers), or a combination of natural and synthetic
fibers. Topsheet 24 is typically employed to help isolate the
wearer's skin from liquids held in absorbent body 26. The topsheet
materials may be composed of a substantially hydrophobic material,
and the hydrophobic material may optionally be treated with a
surfactant or otherwise processed to impart a desired level of
wettability and hydrophilicity. For example, the topsheet can be
treated with about 0.28% Triton X-102 surfactant.
Various woven and nonwoven fabrics can be used for topsheet 24. For
example, the topsheet may be composed of a meltblown or spunbonded
web of polyolefin fibers. The topsheet may also be a
bonded-carded-web composed of natural fibers, synthetic fibers or
combinations thereof.
For the purposes of the present description, the term "nonwoven
web" means a web of material which is formed without the aid of a
textile weaving or knitting process. The term "fabrics" is used to
refer to all of the woven, knitted and nonwoven fibrous webs.
In the shown embodiment of diaper 20, for example, topsheet 24 and
backsheet 22 can be generally coextensive and have length and width
dimensions which are generally larger than the corresponding
dimensions of absorbent body 26. Topsheet 24 is associated with and
superimposed on backsheet 22, thereby defining the periphery of
diaper 20.
Topsheet 24 and backsheet 22 are connected or otherwise associated
together in an operable manner. As used herein, the term
"associated" encompasses configurations in which topsheet 24 is
directly joined to backsheet 22 by affixing topsheet 24 directly to
backsheet 22, and configurations wherein topsheet 24 is indirectly
joined to backsheet 22 by affixing topsheet 24 to intermediate
members which in turn are affixed to backsheet 22. Topsheet 24 and
backsheet 22 can be affixed directly to each other in the diaper
periphery by attachment means (not shown) such as an adhesive
bonds, sonic bonds, thermal bonds or any other attachment means
known in the art. For example, a uniform continuous layer of
adhesive, a patterned layer of adhesive, a sprayed pattern of
adhesive or an array of separate lines, swirls or spots of
construction adhesive may be used to affix topsheet 24 to backsheet
22. It should be readily appreciated that the above-described
attachment means, in desired combinations, may also be employed to
interconnect and assemble together the other component parts of the
article.
Absorbent body 26 can comprise an absorbent pad composed of
selected hydrophilic fibers and high-absorbency particles. The
absorbent body is positioned between topsheet 24 and backsheet 22
to form diaper 20. The absorbent body has a construction which is
generally compressible, conformable, non-irritating to the wearer's
skin, and capable of absorbing and retaining liquid body exudates.
It should be understood that, for purposes of this invention, the
absorbent body may comprise a single, integral piece of material,
or alternatively, may comprise a plurality of individual separate
pieces of material which are operably assembled together.
Various types of wettable, hydrophilic fibrous material can be used
to form the component parts of absorbent body 26. Examples of
suitable fibers include naturally occurring organic fibers composed
of intrinsically wettable material, such as cellulosic fibers;
synthetic fibers composed of cellulose or cellulose derivatives,
such as rayon fibers; inorganic fibers composed of an inherently
wettable material, such as glass fibers; synthetic fibers made from
inherently wettable thermoplastic polymers, such as particular
polyester or polyamide fibers; and synthetic fibers composed of a
nonwettable thermoplastic polymer, such as polypropylene fibers,
which have been hydrophilized by appropriate means. The fibers may
be hydrophilized, for example, by treatment with silica, treatment
with a material which has a suitable hydrophilic moiety and is not
readily removable from the fiber, or by sheathing the nonwettable,
hydrophobic fiber with a hydrophilic polymer during or after the
formation of the fiber. For the purposes of the present invention,
it is contemplated that selected blends of the various types of
fibers mentioned above may also be employed.
As used herein, the term "hydrophilic" describes materials the
surfaces of which are wetted by the contact of aqueous liquids. The
degree of wetting of the materials can, in turn, be described in
terms of the contact angles and the surface tensions of the liquids
and materials involved. Equipment and techniques suitable for
measuring the wettability of particular fiber materials or blends
of fiber materials can be provided by a Cahn SFA-222 Surface Force
Analyzer System. When measured with this system in accordance with
the procedure described in detail herein below, fibers having
contact angles less than 90.degree. are designated "wettable",
while fibers having contact angles greater than 90.degree. are
designated "nonwettable".
Absorbent body 26 can comprise a matrix of hydrophilic fibers, such
as a web of cellulosic fluff, mixed with particles of
high-absorbency material. In particular arrangements, absorbent
body 26 may comprise a mixture of superabsorbent hydrogel-forming
particles and synthetic polymer meltblown fibers, or a mixture of
superabsorbent particles with a fibrous coform material comprising
a blend of natural fibers and/or synthetic polymer fibers. The
superabsorbent particles may be substantially homogeneously mixed
with the hydrophilic fibers, or may be nonuniformly mixed. For
example, the concentrations of superabsorbent particles may be
arranged in a non-step-wise gradient through a substantial portion
of the thickness (z-direction) of the absorbent structure, with
lower concentrations toward the bodyside of the absorbent body and
relatively higher concentrations toward the outerside of the
absorbent structure. Suitable z-gradient configurations are
described in U.S. Pat. No. 4,699,823 issued Oct. 13, 1987 to
Kellenberger et al., the disclosure of which is incorporated herein
by reference to the extent that it is consistent (not in conflict)
with the present description. Alternatively, the concentrations of
superabsorbent particles may be arranged in a non-step-wise
gradient, through a substantial portion of the thickness
(z-direction) of the absorbent structure, with higher
concentrations toward the bodyside of the absorbent body and
relatively lower concentrations toward the outerside of the
absorbent structure. The superabsorbent particles may also be
arranged in a generally discrete layer within the matrix of
hydrophilic fibers. In addition, two or more different types of
superabsorbent may be selectively positioned at different locations
within or along the fiber matrix.
The high-absorbency material may comprise absorbent gelling
materials, such as superabsorbents. Absorbent gelling materials can
be natural, synthetic and modified natural polymers and materials.
In addition, the absorbent gelling materials can be inorganic
materials, such as silica gels, or organic compounds such as
cross-linked polymers. The term "cross-linked" refers to any means
for effectively rendering normally water-soluble materials
substantially water insoluble but swellable. Such means can
include, for example, physical entanglement, crystalline domains,
covalent bonds, ionic complexes and associations, hydrophilic
associations, such as hydrogen bonding, and hydrophobic
associations or Van der Waals forces.
Examples of synthetic absorbent gelling material polymers include
the alkali metal and ammonium salts of poly(acrylic acid) and poly
(methacrylic acid), poly(acrylamides), poly(vinyl ethers), maleic
anhydride copolymers with vinyl ethers and alpha-olefins,
poly(vinyl pyrrolidone), poly(vinylmorpholinone), poly(vinyl
alcohol), and mixtures and copolymers thereof. Further polymers
suitable for use in the absorbent body include natural and modified
natural polymers, such as hydrolyzed acrylonitrile-grafted starch,
acrylic acid grafted starch, methyl cellulose, carboxymethyl
cellulose, hydroxypropyl cellulose, and the natural gums, such as
alginates, xanthan gum, locust bean gum and the like. Mixtures of
natural and wholly or partially synthetic absorbent polymers can
also be useful in the present invention. Other suitable absorbent
gelling materials are disclosed by Assarson et al. in U.S. Pat. No.
3,902,236 issued Aug. 26, 1975. Processes for preparing synthetic
absorbent gelling polymers are disclosed in U.S. Pat. No. 4,076,663
issued Feb. 28, 1978 to Masuda et al. and U.S. Pat. No. 4,286,082
issued Aug. 25, 1981 to Tsubakimoto et al.
Synthetic absorbent gelling materials typically are xerogels which
form hydrogels when wetted. The term "hydrogel", however, has
commonly been used to also refer to both the wetted and unwetted
forms of the material.
To improve the containment of the high-absorbency material,
absorbent body 26 can include an improved overwrap, such as wrap
sheet 28, placed immediately adjacent and around absorbent body 26.
The wrap sheet is preferably a layer of absorbent material which
covers the major bodyside and outerside surfaces of the absorbent
body, and preferably encloses substantially all of the peripheral
edges of the absorbent body to form a substantially complete
envelope thereabout. Alternatively, the wrap sheet can provide an
absorbent wrap which covers the major bodyside and outerside
surfaces of the absorbent body, and encloses substantially only the
lateral side edges of the absorbent body. Accordingly, both the
linear and the inwardly curved portions of the lateral side edges
of the wrap sheet would be closed about the absorbent body. In such
an arrangement, however, the end edges of the wrap sheet may not be
completely closed around the end edges of the absorbent body at the
waistband regions of the article.
Diaper 20 can also include a surge management layer 84 which helps
to decelerate and diffuse surges of liquid that may be introduced
into the absorbent body of the article. In the illustrated
embodiment, for example, surge layer 84 can be located on an
inwardly facing body side surface of topsheet layer 24.
Alternatively, surge layer 84 may be located adjacent to an outer
side surface of topsheet 24. Accordingly, the surge layer would
then be interposed between topsheet 24 and absorbent body 26.
Leg elastic members 34 are located in the lateral side margins 110
of diaper 20 and are arranged to draw and hold diaper 20 against
the legs of the wearer. The elastic members are secured to diaper
20 in an elastically contractible condition so that in a normal
under strain configuration, the elastic members effectively
contract against diaper 20.
In the embodiment illustrated in FIG. 1, leg elastic members 34
extend essentially along the complete length of the intermediate
crotch region 42 of diaper 20. Alternatively, elastic members 34
may extend the entire length of diaper 20, or any other length
suitable providing the arrangement of elastically contractible
lines desired for the particular diaper design.
Elastic members 34 may have any of a multitude of configurations.
The elastic members may comprise a single strand of elastic
material, or may comprise several parallel or non-parallel strands
of elastic material, or may be applied in a rectilinear or
curvilinear arrangement. Where the strands are non-parallel, two or
more of the strands may intersect or otherwise interconnect within
the elastic member. The elastic members may be affixed to the
diaper in any of several ways which are known in the art. For
example, the elastic members may be ultrasonically bonded, heat and
pressure sealed using a variety of bonding patterns, or adhesively
bonded to diaper 20 with sprayed or swirled patterns of hotmelt
adhesive.
In the illustrated embodiments of the invention, leg elastic
members 34 may comprise a carrier sheet (not shown) to which are
attached a grouped set of elastics composed of a plurality of
individual elastic strands 39. The elastic strands may intersect or
be interconnected, or be entirely separated from each other. The
carrier sheet may, for example, comprise a 0.002 cm thick film of
unembossed polypropylene material. The elastic strands can, for
example, be composed of Lycra elastomer available from DuPont, a
business having offices in Wilmington, Del. Each elastic strand is
typically within the range of about 470-1500 decitex (dtx), and may
be about 940-1050 dtx. In particular embodiments of the invention,
for example, three or four strands can be employed for each
elasticized legband.
In addition, leg elastics 34 may be generally straight or
optionally curved. For example, the curved elastics can be inwardly
bowed toward the longitudinal centerline of the diaper with the
innermost point (or apex, relative to the cross-direction of the
article) of the set of curved elastic strands positioned
approximately 0.75-1.5 inches inward from the outer most edge of
the set of elastic strands. In particular arrangements, the
curvature of the elastics may not be configured or positioned
symmetrically relative to the lateral centerline of the diaper. The
curved elastics may have an inwardly bowed and outwardly bowed,
reflex-type of curvature, and the length-wise center of the
elastics may optionally be offset by a selected distance within the
range of about 0-8 cm toward either the front or rear waistband of
the diaper to provide desired fit and appearance.
In the shown embodiment, diaper 20 includes a waist elastic 36
positioned in the longitudinal margins of either or both of front
waistband 38 and rear waistband 40. The waist elastics may be
composed of any suitable elastomeric material, such as an elastomer
film, an elastic foam, multiple elastic strands, an elastomeric
fabric or the like. For example, suitable elastic waist
constructions are described in U.S. Pat. No. 4,916,005 to Lippert
et al., the disclosure of which is hereby incorporated by reference
to the extent that it is consistent (not contradictory)
herewith.
Diaper 20 can also include a pair of elasticized containment flaps
82 which extend longitudinally along the length dimension 86 of the
diaper. The containment flaps are typically positioned laterally
inboard from leg elastics 34, and substantially symmetrically
placed on each side of the lengthwise, longitudinal centerline of
the diaper. Examples of suitable containment flap constructions are
described in U.S. Pat. No. 4,704,116 issued Nov. 3, 1987, to K.
Enloe, the disclosure of which is hereby incorporated by reference
to the extent that it is consistent herewith. The containment flaps
may be composed of a wettable or a non-wettable material, as
desired.
In an optional, alternative embodiment of the invention, diaper 20
may include elasticized waist flaps, such as those described in
U.S. Pat. No. 4,753,646 issued Jun. 28, 1988, to K. Enloe, the
disclosure of which is hereby incorporated by reference to the
extent that it is consistent herewith. Similar to the construction
of the containment flaps, the waist flaps may be composed of a
wettable or non-wettable material, as desired. The waist and/or
containment flap materials may be fluid impermeable, permeable to
gas, or permeable to both gas and liquid.
Absorbent article structures suitable for use with the present
invention are described in U.S. patent application Ser. No.
07/757,778 of D. Proxmire et al., filed Sep. 11, 1991, and entitled
"ABSORBENT ARTICLE HAVING A LINER WHICH EXHIBITS IMPROVED SOFTNESS
AND DRYNESS, AND PROVIDES FOR RAPID UPTAKE OF LIQUID" (Attorney
Docket No. 9932), now U.S. Pat. No. 5,192,606 issued Mar. 9, 1993,
the disclosure of which is hereby incorporated by reference to the
extent that it is consistent with the present specification. Other
absorbent article structures suitable for use with the present
invention are described in U.S. patent application Ser. No.
07/757,760; "THIN ABSORBENT ARTICLE HAVING RAPID UPTAKE OF LIQUID";
of W. Hanson et al. filed Sep. 11, 1991 (Attorney Docket No. 9922),
the disclosure of which is hereby incorporated by reference to the
extent that it is consistent herewith.
To provide a refastenable adhesive taping system, diaper 20 can
include a supplemental landing zone patch 46, which provides a
target zone for receiving an adhesive attachment of tape fasteners
44 thereon. In the illustrated embodiment of the invention, landing
zone patch 46 is positioned on the outward surface of backsheet 22
and is located on the second, front waistband portion 38 of the
diaper. Landing zone patch 46 is constructed of a suitable
material, such as polypropylene, polyester, or the like, and is
configured and arranged to accept a secure adhesion of tape
fasteners 44. In addition, the landing zone patch and the tape
fasteners are cooperatively constructed and arranged to provide a
releasable adhesion which allows the tape fastener to be removed
from the landing zone patch for repositioning and re-adhesion
without tearing or excessively deforming the material of backsheet
22. For example, a suitable tape landing zone construction is
described in U.S. Pat. No. 4,753,649 issued to Pazdernik, the
disclosure of which is hereby incorporated by reference to the
extent that it is consistent herewith.
In various embodiments of the invention, a tape fastener 44 can be
located at either or both of lateral end regions 116 and 118 of
either or both of waistbands 38 and 40, respectively. The
representatively shown embodiment has the tape fasteners located at
the terminal side edges of rear waistband 40.
Articles which include separate panel-and-fastener sections which
can be constructed with the method of the present invention are
described in copending U.S. patent application Ser. No. 168,615
entitled "DYNAMIC FITTING DIAPER" filed Dec. 16, 1993 by T.
Roessler et al. (Attorney Docket No. 10,961). The disclosure of
this document is hereby incorporated by reference to the extent
that it is consistent herewith.
With reference to FIGS. 1 and 2, for example, each side panel 90
extends laterally from the opposed lateral ends of at least one
waistband portion of backsheet 22, such as rear waistband portion
40, to provide terminal side sections of the article. In addition,
each side panel can substantially span from a laterally extending,
terminal waistband edge 106 to approximately the location of a
corresponding leg opening section of the diaper. Diaper 20, for
example, has a laterally opposed pair of leg openings formed by
appointed, medial sections of the shown pair of longitudinally
extending, side edge regions 110. In the various configurations of
the invention, the side panels may be integrally formed with a
selected diaper component. For example, side panels 90 can be
integrally formed from the layer of material which provides
backsheet layer 22, or may be integrally formed from the material
employed to provide topsheet 24. In alternative configurations, the
side panels 90 may be separate members that are connected to
backsheet 22, to topsheet 24, in between the backsheet and
topsheet, or combinations thereof.
In particular aspects of the invention, each of the side panels 90
may be formed from a separate piece of material which is then
suitably assembled and attached to the selected front and/or rear
waistband portion of the diaper article. In the illustrated
embodiments of the invention, for example, side panels 90 are
attached to the rear waistband portion of backsheet 22, and can be
operably attached to either or both of the backsheet and topsheet
components of the article. The side panels extend laterally to form
a pair of opposed waist-flap sections of the diaper, and are
attached with suitable connecting means, such as adhesive bonding,
thermal bonding, ultrasonic bonding, clips, staples, sewing or the
like.
As previously mentioned, various suitable constructions can be
employed to attach the side panels 90 to the selected waistband
portions of the article. Where the side panels are composed of an
elastomeric material, for example, suitable constructions for
securing a pair of elastomeric, stretchable members to the lateral,
side portions of an article to extend laterally outward beyond the
opposite side regions of the outer cover and liner components of an
article can be found in U.S. Pat. No. 4,938,753 issued Jul. 3, 1990
to P. VanGompel et al., the disclosure of which is hereby
incorporated by reference to the extent that it is consistent
herewith.
In conventional fastening systems, the fastening stress is applied
to the factory bond between fastening tab 44 and the side sections
of rear waistband 40 substantially across the base length 58 of the
fastening tab. As a result, relatively low levels of stress are
applied to the regions of the ear sections that are longitudinally
adjacent to the side edges of the fastening tab. As a result, the
longitudinally adjacent regions tend to wrinkle and curl away from
the body of the wearer. The wrinkling and curling can be unsightly
and can create gaps along the waistband and along the leg opening
region of the diaper through which waste materials may leak from
the diaper. Attempts to address this problem have employed complex
fastening systems which extend along substantially the entire free
edge length of the ear sections of the article. Other attempts to
address this problem have employed multiple fastening tapes or a
large, wide fastening tab. The wide fastening tabs or tapered
fastening tabs have transmitted excessive stresses to the user-bond
securement section of the fastening system. Such stresses can tend
to undesirably disconnect the user bond portion of the fastening
system when the wearer shifts and moves about. In addition, such
configurations may not sufficiently conform and adjust to the
movements of the wearer, and can result in excessive irritation of
the wearer's skin.
To help address the problems associated with conventional fastening
systems such as those described above, the present invention can
advantageously provide for a distinctive reinforcement, stress beam
section 98. The stress beam can disperse and dissipate the
fastening forces across the length of each side panel 90. In
addition, the stress beam section can provide for a sufficient
stiffening and reinforcement of its associated waistband section to
help prevent undesired and excessive wrinkling, necking-down or
folding-over of the lateral end of the waistband or side panel
during the use of the article.
In the various configurations of the invention, stress beam section
98 can be integrally formed from the same material employed to form
the side panel 90 associated therewith. For example, a portion of
the free end of a side panel may be doubled over one or more times
along longitudinally extending fold lines to generate an operable
stress beam section. Alternatively, the stress beam section can be
provided by densifying or embossing a selectively sized and shaped
region of side panel 90 to an extent which provides operable levels
of strength and stiffness.
In other arrangements of the invention, stress beam section 98 can
include a stiffening or reinforcement member provided by a
selectively shaped and sized region of material which is integrally
formed with fastening tab substrate 48. Alternatively, the stress
beam section can include a separate stiffening or reinforcement
member 97 which is appropriately configured, and is assembled to
the free end region of the side panel. For example, the stress beam
section can be provided for by a suitably sized and shaped piece of
material attached to a suitable surface of each side panel 90, such
as an inward bodyside surface of each panel. The material may be
composed of a polymer film, a nonwoven fabric, a woven fabric or
the like, as well as combinations thereof. In a particular
configuration, the stress beam section can include a stiffening
member composed of the material employed to construct release tape
material 74 and/or fastening tab substrate 48. In the various
configurations of the invention the stress beam section can be
substantially non-extensible and/or substantially
non-elastomeric.
With reference to FIG. 2, a stress beam section 98 can be operably
connected to each side panel 90 along the free end region 92 of the
side panel with suitable attaching means, such as adhesive bonding,
thermal bonding, ultrasonic bonding, clips, staples, sewing or the
like. The stress beam section has a laterally extending,
cross-directional width dimension 100 and a longitudinally
extending length dimension 102. To obtain desired performance, it
can be advantageous to position stress beam section 98 at a medial
location along the length of side panel 90. In the shown
embodiment, for example, the stress beam section is substantially
centered along the longitudinal length of the free end section of
the side panel. A particular aspect of the invention can be
configured to employ a separate piece of material which operatively
forms a member that overlaps the material of side panel 90 to
provide for the desired stress beam section 98.
In other aspects of the invention, stress beam section 98 extends
along the longitudinal length of side panel 90 to be substantially
coterminous with the laterally extending waistband edge 106 of the
article. In the illustrated embodiment, fastening tab 44 is
approximately centered along the length of stress beam section 98.
Alternatively, the location of fastening tab 44 may be offset
longitudinally of the diaper by a selected distance away from the
lengthwise center of stress beam section 98.
A fastening means, such as provided by fastening tape tab 44, is
operably connected to each of the side panels 90. In the
illustrated configuration, the juncture section along which
fastening tab 44 intersects the terminal side edge of panel 90
provides a relatively narrowed panel juncture region 80. The
connection may be accomplished with suitable attaching means, such
as adhesive bonding, thermal bonding, ultrasonic bonding, clips,
staples, sewing or the like. Alternatively, the fastening tab
substrate may be integrally formed from the material employed to
form stress beam section 98. In optional configurations, the
fastening tab may be directly or indirectly connected to the stress
beam section 98 associated with the respective side panel. For
example, the fastening tab 44 may indirectly connect to its
associated stress beam section 98 by way of an intervening section
of side panel 90.
In the illustrated embodiments of the invention, the components of
the fastening means cooperate to secure the front and rear
waistband portions of the article about a wearer. In particular,
the rear waistband section of the shown embodiment overlaps the
front waistband section of the article and the fastening means
operably attaches to appointed regions of the front waistband
portion.
Fastening tab 44 has a longitudinally extending length dimension
and a laterally extending width dimension. In addition, the
fastening tab has a base section 56, a user bond end section 60 and
an intermediate section 64 which interconnects the base and end
sections. Base section 56 has a longitudinal length dimension 58,
end section 60 has a longitudinal length dimension 62, and
intermediate section 64 has a longitudinal length dimension 66.
In particular aspects of the invention, fastening tab 44 has, along
its respective panel juncture region 80, a base length 58 which is
not more than about 90 percent of the length 102 of stress beam
section 98. Alternatively, the fastening tab base length is not
more than about 80 percent of the stress beam section length, and
optionally is not more than about 50 percent of the stress beam
section length to provide desired performance. In other aspects of
the invention, fastening tab 44 has a base length 58 which is not
less than about 1 percent of the length 102 of stress beam section
98. Alternatively, the base length is not less than about 5 percent
of the stress beam section length, and optionally is not less than
about 20 percent of the stress beam section length to provide
desired benefits. Accordingly, when the fastening means is employed
to secure the article on the wearer, the end sections 104 of the
stress beam section are not further attached to the front waistband
of the article by the operation of securing the article on the
wearer. As a result, the unattached end sections 104 can
advantageously slide, bend and otherwise move relative to the
secured portions of the article without excessively disturbing the
securing attachment between the user bond section of the fastening
tab and the appointed securement zone of the article.
In the illustrated embodiments length 58 of the base section 56 of
fastening tab 44 is relatively larger than the length 66 of the
fastening tab intermediate section 64. Alternatively, however, base
length 58 may be equal to or less than the intermediate section
length 66. In either case, the construction of the fastening system
of the invention can provide a seam section 69 the fastening tab
which is positioned between stress beam section 98 and the user
bond section 52 of the fastening tab. As determined when the
fastening tab in its relaxed and substantially untensioned
condition, the tab seam section generally represents the narrowest
region of the fastening tab with respect to those portions of the
fastening tab that are spaced from the terminal end sections of the
tab. Seam section 69 can advantageously provide a relatively more
flexible pivot region which can facilitate a freer, less restricted
relative movement between the stress beam portion of the fastening
system and user bond portion of the fastening tab. As a result, the
stress beam 98 can operate to help maintain the desired waistband
appearance and good fit during the movements of the wearer, and the
user bond section 52 can maintain a more reliable securement with
less occurrence of undesired pop-opens. The seam section can help
isolate the user bond section of the fastening system from the
self-adjusting movements of the side panels 90 and the stress beam
sections of the fastening system. In the shown embodiment, the seam
section 69 is composed of a substantially non-extensible and
substantially non-elastomeric material, but may alternatively be
composed of an elastomeric material which is operably assembled or
otherwise incorporated into the fastening tab structure.
In the various embodiments of the invention, fastening tab 44 can
be configured to provide an adhesive fastening mechanism. More
particularly, the user bond section 52 of fastening tab 44 can
include a layer of primary adhesive 54 disposed across an appointed
attaching surface 68 of fastening tab substrate 48. The adhesive is
configured to provide a desired level of adhesion and securement
when applied against the appointed landing zone region of the
article. In addition, the adhesive can be configured to be capable
of being removed and refastened one or more times onto the
appointed landing zone region. An example of a suitable
refastenable taping system is described in U.S. Pat. No. 5,147,347
issued Sep. 15, 1992 to Y. Huang et al., the disclosure of which is
hereby incorporated by reference to the extent that it is
consistent herewith.
In various alternative configurations of the invention, the
fastening means may be provided by interlocking, mechanical-type
fasteners such as hooks, buckles, snaps, buttons and the like. In
particular aspects of the invention the fastening means can be
provided by a hook-and-loop fastener system, a mushroom-and-loop
fastener system or the like (hereinafter hook-and-loop fastener).
Such fastening systems generally comprise a "hook" component and a
cooperating "loop" component which engages and interlocks with the
hook component. Such systems are, for example, available under the
VELCRO trademark. Examples of suitable hook-and-loop fastening
systems are described in U.S. Pat. No. 5,019,073 issued May 28,
1991 to T. Roessler et al., the disclosure of which is hereby
incorporated by reference to the extent that it is consistent
herewith. In a typical configuration of a hook-and-loop fastening
system, a portion of hook material is operably connected to the
attaching surface 68 of fastening tab substrate 48, and the loop
material is employed to construct a cooperating landing zone 46.
The landing zone patch, for example, can be suitably attached to
the appointed landing zone region on the outside surface of
backsheet 22. An alternative configuration of a suitable
hook-and-loop fastening system may have the loop material secured
to the attaching surface 68 of fastening tab substrate 48.
Accordingly, a region of hook material would be employed to form
landing zone patch 46.
Fastening tab 44 can advantageously have a stiffness value which is
different than the stiffness value of stress beam 98. As a result,
fastening tab 44 can be selectively configured with a user bond
section 52 which is capable of being fastened, removed and
refastened without excessively distorting or tearing the appointed
landing zone region of the article. The selective tailoring of the
characteristics of fastening tab 44 can be accomplished while
retaining the desired stress beam characteristics of stress beam
section 98. The stress beam section retains its ability to spread
forces across the free end length 94 of side panel 90 without
adversely affecting the fastening and refastening capability of
fastening tab 44.
In particular aspects of the invention, the user bond end section
60 of fastening tab 44 can have an end length 62 which is greater
than the length 66 of the intermediate section 64 of the fastening
tab, as representatively shown in FIG. 2. In the illustrated
embodiment, for example, the end length can correspond to the
widest length dimension of the user bond section 52 of the
fastening tab. In other aspects of the invention, the length 62 of
end section 60 can also be greater than the length 58 of base
section 56 of the fastening tab.
More particularly, end length 62 can be at least about 10 percent
greater than intermediate length 66. Alternatively, the end length
can be at least about 20 percent greater than the intermediate
length, and optionally can be at least about 40 percent greater
than the intermediate length. In other aspects of the invention,
end length 62 can be not more than about 500 percent greater than
intermediate length 66. Alternatively, the end length 62 is not
more than about 100 percent greater than intermediate length 66,
and optionally is not more than about 60 percent greater than the
intermediate length.
End length 62 can be at least about 2 percent greater than base
length 58. Alternatively, end length 62 can be at least about 20
percent greater than base length 58, and optionally can be at least
about 40 percent greater than the base length. In other aspects,
end length 62 can be not more than about 500 percent greater than
base length 58. Alternatively, end length 62 can be not more than
about 100 percent greater than base length 58, and optionally is
not more than about 60 percent greater than the base length of the
fastening tab to provide desired performance.
In the illustrated embodiment, for example, intermediate section 64
of fastener tab 44 can be configured to provide an expanding area
of the fastener tab. The expanding area provides a gradual
transition between base length 58 and end length 62. To avoid the
generation of excessive stress concentrations that might initiate
undesired fractures, the transition area is substantially free of
sharp notches or abrupt angles.
The relatively smaller base and/or intermediate lengths of tab 44
can advantageously contribute to the improved performance provided
by the invention. The relatively larger length at the end portion
of the user bond section 52 helps provide for a larger user bonding
area which can improve the security of the fastening system. At the
same time, the relatively smaller length at the base and/or
intermediate portions of tab 44 can provide for a relatively
greater ease of bending and/or twisting or other movement, as
compared to the user bond portion of the tab. As a result, the
fastening securement can be maintained at high levels while
allowing substantially continual, dynamic fit adjustments at the
points of interconnection between the front and rear waistband
sections of the article.
With reference to FIGS. 2 and 3, a tape fastener tab 44 can
comprise a tape substrate member 48 having the desired fastening
means, such as primary adhesive layer 54, located and disposed on a
major facing surface thereof, such as surface 68. The fastener tab
provides a factory-bond section 50 for connecting the tape
substrate member to a selected portion of diaper 20, and a
user-bond section 52 for connecting and securing the waistband
sections of the diaper about the body of a wearer. In a particular
aspect of the invention, the factory-bond section of fastener tab
44 is attached to the free end region 92 of side panel 90, and is
constructed and configured to provide stress beam section 98.
The factory-bond region 50 of tape fastener 44 is appointed for
securement onto the desired section of its associated article
during the manufacture of the article. The user-bond region 52 of
tape fastener 44 is appointed for securing the article on a wearer
during use. The representatively shown embodiment of the tape
fastener, for example, has primary adhesive layer 54 applied onto a
selected surface thereof to provide an adhesive fastening system.
In the illustrated embodiment of diaper 20, the factory-bond region
50 of tape fastener 44 is attached to the lateral ends of rear
waistband 40, and the user-bond region 52 of the tape fastener is
employed to attach the lateral ends of rear waistband 40 to the
corresponding lateral ends of front waistband 38 to secure the
diaper about the waist of a child. User-bond section 52 connects to
a finger tab 70 which includes a substantially non-attaching
grasping section 72 thereof. The grasping section can, for example,
comprise a layer of exposed absorbent material, and at least a
portion of the exposed absorbent material can be operably
positioned and arranged to face in the same direction as an
appointed inward face of the tape fastener.
With an adhesive fastening tab, a primary adhesive layer 54 can be
disposed upon an appointed inwardly facing surface of substrate
member 48. The portion of adhesive positioned on factory-bond 50
can be employed to assemble tape fastener 44 onto diaper 20 during
the manufacture of the diaper. The portion of adhesive layer 54
located on user-bond region 52 can be employed to secure the diaper
onto an infant. The particular adhesive parameters of adhesive
layer 54 can be selected and tailored to meet desired adhesive
properties, such as adhesive shear strength and adhesive peel
strength.
Suitable materials for constructing fasteners 44, such as sheet
materials for constructing substrate member 48 and adhesive
materials for constructing layer 54, are available from various
manufacturers, such as 3M Company, a business having a Disposable
Products Division with offices in the 3M Center, St. Paul, Minn.;
and Avery International, a business having a Specialty Tape
Division with offices in Painesville, Ohio.
The illustrated embodiment of the tape fastening system includes a
release tape member 74 for releasably holding user-bond region 52
of the tape fastener in a storage position which protects the
user-bond region of primary adhesive layer 54 against contamination
or premature adhesion against other portions of diaper 20. In the
illustrated embodiment, release tape 74 is positioned in a
superposed, adjacent relation with substrate member 48, and is
attached to an interior surface of diaper 20. The representatively
shown embodiment of release tape 74 includes an anchor surface 76
and an opposite release surface 78. Anchor surface 76 has disposed
thereon a suitable anchor adhesive layer, and release surface 78
has disposed thereon a selected layer of an operable release
coating, such as a coating composed of cured (cross-linked) poly
dimethyl siloxane (PDMS). Suitable release tapes are commercially
available from vendors such as 3M Company and Avery International.
For example, suitable release tape materials include the FT-4430
material available from Avery International. The release tape
material includes a release surface against which the adhesive
bearing surface of the fastening tab can be stored and protected
from contamination. The fastening adhesive, however, readily
separates from the release surface when desired.
In a particular embodiment of the invention, a terminal end portion
of release tape 74 may optionally overlap and adhesively bond to an
intermediate section of substrate member 48 along a bond region
which traverses across the length of the substrate member. The
resultant interconnection between substrate member 48 and release
tape 74 provides for a Y-bond which can strengthen the assembly and
attachment of tape fastener 44 to the section of diaper 20 that is
clamped between release tape 74 and factory-bond region 50 of tape
substrate member 48. In other aspects of the invention, release
tape 74 can be constructed and configured to provide for stress
beam section 98.
The user-bond region of tape substrate member 48 has a distal end
section 108 which is appointed for grasping by the user to suitably
position and adhere the user-bond region of tape fastener 44 to an
appointed tape securement zone of the article. In the illustrated
embodiment, for example, the user will typically grasp end section
108 to adhere the tape fastener against landing zone patch 46.
Distal end section 108 can be constructed to be non-adhering and
non-securing so that the end section can be more easily found and
lifted by the user.
In a particular aspect of the invention, tape fastener 44 can
include a separate finger tab member 70 connected to substrate end
section 60 along an attachment region. In an optional configuration
of the invention, finger tab 70 may be constructed by providing a
particular physical or chemical treatment applied to end section 60
of substrate member 48. In the illustrated embodiment, for example,
the finger tab can be a layer of release tape material. In
alternative configurations, the treatment can be configured to
impart desired absorbency and/or tactile characteristics to the
gripping region of the resultant finger tab. In yet other aspects
of the invention, finger tab 70 can be composed of a material which
is capable of absorbing selected amounts of contaminants, such as
powders, liquids, and creams, which may be carried on the fingers
of the user. The material of finger tab 70 may substantially end at
the longitudinally terminal edge of the tab substrate member.
Alternatively, finger tab 70 may extend beyond the terminal edge of
the tape substrate member.
The process of the invention provides a distinctive method for
forming a plurality of tape fasteners 44 having an improved shape
and configuration. An aspect of the process of the invention can
also be configured to provide a plurality of fastener tabs 44
connected to a web of side panel material. In particular
configurations the side panel material can be elastomeric. The
process can be advantageously employed in-line with an operation
for manufacturing a selected article, such as a disposable diaper,
incontinence garment, feminine care article, gown, garment or the
like. The resultant process can be configured to rapidly form a
plurality of individual tape fasteners operably connected to side
panel members, and then assemble the panel-and-fastener components
to the selected article. The process can also be configured to
assemble a release tape component to the article, as desired.
In the process aspect of the invention representatively shown in
FIGS. 4 and 4A, a method for forming a plurality of fasteners
includes the step of providing a substantially continuous web of
substrate material along a selected, longitudinal machine-direction
132. The substrate web has a laterally extending cross direction
134 which is substantially perpendicular to the machine direction,
and has laterally opposed, longitudinally extending, first and
second side edge regions 142 and 144 thereof. A selected fastening
means, such as a layer of primary adhesive 54, is positioned and
applied onto a major facing surface 186 of the substrate web 140. A
first longitudinally extending web of stiffening material 154 is
attached to the major surface of substrate web 140 at a location
which is proximate a first side edge region 142 of the substrate
web. A second longitudinally extending web of stiffening material
156 is attached to the major surface of substrate 140 at a location
which is proximate the second side edge region 144 of substrate web
140. The web of substrate material and the webs of stiffening
material thereby form a substrate composite 192. The substrate web
is separated along a longitudinally extending medial region
thereof, with a substantially regularly undulating serpentine
separation line 158 to provide an opposed pair of fastener tab
subassemblies 194 and 196. At least one fastener tab subassembly,
and preferably both fastener tab subassemblies 194 and 196 can be
divided along a plurality of division lines 208 which extend
substantially laterally across the at least one assembly to provide
a plurality of fastener tab components 166. Each of the fastener
tab components has an appointed factory bond region 50 thereof.
In the various aspects and configurations of the invention
described herein, the webs of stiffening material can be provided
by a first web of release material 182 and a second web of release
material 184. Accordingly, with reference to FIGS. 5 and 5A, the
web of substrate material 140 has a major facing surface 186
thereof, and has first and second side edge regions 142 and 144,
respectively. A component of a primary fastening means, such as a
layer of primary adhesive 54, is provided across the major surface
of substrate web 140. A first securement surface 188 of a side edge
portion of the first web of release material 182 is attached to the
first side edge region 142 of the substrate web 140. The first
release web 182 has a release surface 232 thereof, which is
positioned opposite the securement surface of the release web. The
release surface is constructed to releasably connect to the
selected component of the primary fastening means. A second
securement surface 190 at a side edge region of the second web of
release material 184 is attached to the second side edge region 144
of substrate web 140. The second release web 184 has a release
surface 234 thereof which is positioned opposite the second
securement surface 190. The release surface is constructed to
releasably connect to the selected component of the primary
fastening means. The substrate web and the first and second release
webs thereby form a substrate composite 192. A medial region of the
substrate web 140 is separated along a generally longitudinally
extending serpentine line 158 to provide at least first and second
fastener tab subassemblies 194 and 196.
In the various configurations of the invention, at least one
fastener tab subassembly, and preferably both fastener tab
subassemblies 194 and 196 can be divided along a plurality of
division lines 208 which extend substantially laterally across the
at least one assembly to provide a plurality of fastener tab
components 166. As representatively shown in FIG. 4C, each of the
fastener tab components has an appointed factory bond region 50
thereof which can be employed to operably connect at least one of
the fastener tabs to each of a pair of lateral side regions of an
appointed waistband portion of an article.
Further aspects of the invention can include the steps of attaching
a first longitudinally extending web of side panel material to an
outboard side region of the first fastener tab subassembly, and
attaching a second longitudinally extending web of side panel
material to an outboard side region of the second fastener tab
subassembly. In particular configurations, either or both of the
side panel webs can be composed of an elastomeric material which is
elastically stretchable at least along a cross-direction of the
side panel webs. The fastener tab subassemblies can be separated
along appropriately selected division lines 164 (FIG. 7) to provide
a plurality of panel-and-fastener components which can be operably
connected to each of a pair of lateral side regions of an appointed
waistband portion of an article. Suitable techniques for such
operations are described below.
In the various aspects of the invention described herein, the
generally longitudinally extending, substantially regularly
undulating, serpentine separation line 158 can optionally and
desirably include substantially regularly alternating,
longitudinally retroceding portions 168 and 170 thereof. The
retroceding portions of the separation line can be configured to
provide for a fastening tab having a seam section 69 which is
relatively narrower than the major portion of the user bond section
52 of the fastening tab 44. More particularly, the retroceding
portions of the separation line can be arranged to provide the
relatively narrower base sections 56 and intermediate sections 64
of the subsequently produced fastening tabs 44. In the shown
configurations, serpentine line 158 also includes traversing
sections 242 which generally extend laterally along the
cross-direction 134 of the process. Serpentine line 158 can be
produced by various conventional techniques, such as die-cutting,
water-cutting, thermal-cutting and the like.
In one aspect of the invention, the traversing sections 242 of the
serpentine line can be configured to extend along a distance which
extends to intrude into at least a portion of each release tape web
182 and 184, as representatively shown in FIG. 5. As a result, with
respect to an individual fastening tab 44, the material from one
release tape web helps to provide for the stress beam section 98
associated with the particular fastening tab 44, and the material
from the second, oppositely located release tape web provides the
material for forming an appropriate finger tab 70 associated with
the particular fastening tab 44.
The process of the invention can further be configured to form a
plurality of stretch panel fasteners. For example, in an aspect of
the invention representatively shown in FIG. 6, a first web of side
panel material, such as first a stretchable web 130, can be
connected to a laterally outboard side edge region 198 of the tape
substrate composite 192 to form a first, panel-and-fastener
composite subassembly, such as first subassembly 160. More
particularly, the stretchable web can be attached to the substrate
web at a location which corresponds with the appointed factory bond
regions of the individual fasteners formed from the first
composite, fastener tab section 194. A second web of side panel
material, such as second stretchable web 136, can be connected to a
laterally outboard side edge region 200 of the second substrate
composite section 196 to form at least a second, panel-and-fastener
composite subassembly, such as subassembly 162. Stretchable web 136
can be attached to the substrate web at a location which
corresponds with the appointed factory bond regions of the
individual fasteners formed from the second composite, fastener tab
section 196. In particular configurations, either or both webs of
side panel material can be constructed of an elastomeric material
which is elastically stretchable at least along the cross-deckle
direction 134 of the method. The panel-and-fastener subassemblies
are separated along appropriately selected, cross-directional
dividing lines 164 to produce a plurality of individual
panel-and-fastener components 166.
An alternative aspect of the process of forming a plurality of
stretch panel fasteners can be arranged to connect the factory bond
regions 50 of a plurality of the fastener tab components 44 to at
least one longitudinally extending side edge region 146 of a
substantially continuous web of elastomerically stretchable
material 130, as representatively shown in FIG. 7. Web 130 is
elastomerically stretchable at least along cross direction 134. The
elastomerically stretchable web 130 can be severed along a
plurality of division lines 164 to provide a plurality of composite
panel-and-fastener components 166.
In other aspects of the invention, the factory bond regions 50 of a
plurality of fastener tab components 44 can optionally be connected
to first and second laterally opposed, longitudinally extending
side edge regions 146 and 147 of the elastomerically stretchable
web 130. The fastener tab components connected to the first side
edge region 146 are offset along machine direction 132 relative to
the fastener tab components connected to the second side edge
region 147 of web 130. The amount of offset spacing between
consecutive, laterally extending centerlines of successive fastener
tabs 44 can, for example, generally correspond to the desired
extent of an appointed side panel member 90 along the longitudinal
direction of the intended article of manufacture.
A further aspect of the method of the invention, representatively
shown in FIG. 8, includes the step of dividing at least one of the
fastener tab subassemblies 194, and preferably both fastener tab
subassemblies 194 and 196, along a plurality of division lines 208
which extend substantially laterally across the at least one
fastener tab subassembly to provide a plurality of adjacently
connected, longitudinally-paired fastener tab component sets 210
having an appointed factory bond regions 50 thereof. The factory
bond regions of a plurality of the longitudinally-paired fastener
tab sets 210 can be connected to at least one longitudinally
extending side edge region 146 of a substantially continuous web of
elastomerically stretchable material 130. Elastomeric web 130 can
be severed along a plurality of severance lines 164 which extend
substantially laterally across the stretchable web and
substantially between the adjacently located fastener tabs 44 and
44a forming a fastener tab set 210. The severance lines may
optionally have a selected contour, as needed to provide a
plurality of composite panel and fastener components 166 having a
desired size and shape.
For example, in a particular configuration of the invention
representatively shown in FIG. 9, a first plurality of the
longitudinally-paired fastener tab component sets 210 can be
connected to a first longitudinally extending side edge region 146
of elastomeric web 130 and a second plurality of the
longitudinally-paired fastener tab sets 210 can be connected to a
second laterally opposed longitudinally extending side edge region
147 of the elastomeric web 130. The fastener tab component sets
connected to the first side edge region 147 are offset along
machine direction 132 relative to the fastener tab component sets
connected to the second side edge region 146. The amount of offset
spacing between consecutive, laterally extending centerlines of
successive, longitudinally-paired fastener tab sets 210 can, for
example, generally correspond to twice the desired extent of an
appointed side panel member 90 along the longitudinal direction of
the intended final article of manufacture. Alternative
configurations of the process can have each of the longitudinally
paired fastener tab component sets 210 connected along a single
side edge of the elastomeric web 130. The resultant composite
assembly can be separated along selected contoured division lines
164 to provide longitudinally-paired, panel-and-fastener components
178.
It should be appreciated that the various steps in the method of
the invention can be conducted in various other sequences to arrive
at substantially the same result. For example, with reference to
FIG. 10, the method for forming a plurality of stretch panel
fasteners can include the step of providing a first, substantially
continuous web of elastomerically stretchable material 130
extending along a selected, longitudinal machine-direction 132. The
first stretchable web 130 is elastomerically stretchable at least
along a laterally extending cross direction 134 which is
substantially perpendicular to machine direction 132. At least a
second, substantially continuous web of elastomerically stretchable
material 136 is delivered along machine direction 132. The second
web of stretchable material 136 is elastomerically stretchable at
least along cross-direction 134, and is laterally spaced from the
first web of stretchable material 130 by a selected distance 138
along the cross direction. A substantially continuous web of
substrate material 140 is provided along machine direction 132 at a
location which is between the first and second webs 130 and 136,
respectively, of stretchable material. Substrate web 140 has
laterally opposed longitudinally extending side edge regions 142
and 144 thereof. A longitudinally extending lateral side edge
region 146 of the first web 130 of stretchable material is attached
to the first side edge region 142 of substrate web 140 to provide a
first bonded region 148. A longitudinally extending lateral side
edge region 150 of the second web 136 of stretchable material is
attached to the second side edge region 144 of substrate web 140 to
provide a second bonded region 152. A first longitudinally
extending web of stiffening material 154 is laid to overlap first
bonded region 148, and is operably connected to the first web of
stretchable material 130 and to substrate web 140. In particular,
the first web of stiffening material 154 can connect to side edge
region 146 of stretchable web 130 and to the first side edge region
142 of substrate web 140. A second longitudinally extending web of
stiffening material 156 is laid to overlap second bonded region
152, and is operably connected to the second web of stretchable
material 136 and to substrate web 140. In particular, stiffening
web 156 can connect to side edge region 150 of the second
stretchable web and to second side edge region 144 of substrate web
140. Substrate web 140 is separated along a longitudinally
extending medial region thereof with a substantially regularly
undulating serpentine separation line 158 to provide an opposed
pair of composite subassemblies 160 and 162. At least one
subassembly, and preferably both subassemblies, are divided along a
plurality of division lines 164 which extend substantially
laterally across each subassembly to provide a plurality of
combined panel-and-fastener components 166.
The overlapping of stiffening webs 154 and 156 can operate to
provide for stress beam sections 98 on the individual fastening
tabs 44. The material of stiffening webs 154 and 156 can be any
material suitable for imparting the desired stiffness level to the
appointed stress beam sections 98 of the individual fastening
systems. Particular configurations of the invention employ
stiffening webs composed of the material employed to provide
release tape sections 74 for the individual fastener tabs 44.
In particular arrangements of the invention, the first stiffening
web can have an outboard side region thereof which extends
laterally beyond and away from the first side edge region 142 of
substrate web 140, and the first web of side panel material can be
attached to the outboard side region of the first stiffening web to
form the first panel-and-fastener subassembly. Similarly, the
second stiffening web can have an outboard lateral side region
thereof which extends laterally beyond and away from the second
side edge region 144 of the substrate web 140, and the second web
of side panel material can be attached to the outboard side region
of said second stiffening web to form the second panel-and-fastener
subassembly.
In the various aspects of the invention described herein, the
process can further include the step of securing at least one of
the panel-and-fastener components 166 to each of a selected pair of
opposed, laterally spaced end regions 172 of appointed waistband
sections 174 of an article web 176, as representatively shown in
FIG. 11. The article web may, for example, include the material
employed to produce back sheet 22 of diaper 20. The article web may
also include the material employed to produce the topsheet 24 or
other component of the end product article, and may optionally
include individual absorbent bodies 26 assembled therewith. A
securement 246 (FIG. 14A) may be provided by a suitable attaching
mechanism, such as adhesive bonding, thermal bonding, ultrasonic
bonding, clips, staples, sewing or the like.
In particular aspects of the invention, at least one composite
subassembly 160, and preferably both subassemblies 160 and 162, can
be divided along a selected plurality of division lines 164 which
are configured and arranged to extend substantially laterally
across each subassembly to provide a plurality of longitudinally
paired, combined panel-and-fastener components 178 (FIG. 9). At
least one of the longitudinally paired panel-and-fastener
components 178 can be secured to each of two opposed, laterally
spaced side regions 172 of an appointed waistband section 174 of an
article web 176 to provide a composite article web 180 (FIG. 11).
The composite article web is severed along a cross-direction 134
thereof at a location 206 which operably divides each of the
longitudinally paired panel-and-fastener components 178 into two
individual panel-and-fastener components 166.
In optional configurations of the invention, the method can include
the step of superposing a web of release tape material 182 onto the
medial section of substrate web 140. Release tape web 182 is
arranged to place release surface 78 against the primary adhesive
layer 54 on substrate web 140. In this configuration of the
invention, the forming of serpentine separation line 158 severs
both substrate web 140 and release tape web 182 during the course
of providing the opposed pair of composite subassemblies 160 and
162, or 194 and 196. The securing surface 188 of the release tape
web can be employed to anchor the subsequently formed individual
release tape members to suitable portions of the final article,
such as an inner bodyside surface of diaper 20.
With reference to FIG. 12, the method for forming a plurality of
stretch panel fasteners can include the step of providing a first,
substantially continuous web of elastomerically stretchable
material 130 extending along a selected, longitudinal
machine-direction 132. The first stretchable web 130 is
elastomerically stretchable at least along a laterally extending
cross direction 134 which is substantially perpendicular to machine
direction 132. At least a second, substantially continuous web of
elastomerically stretchable material 136 is delivered along machine
direction 132. The second web of stretchable material 136 is
elastomerically stretchable at least along cross-direction 134, and
is laterally spaced from the first web of stretchable material 130
by a selected distance 138 along the cross direction. A
substantially continuous web of substrate material 140 is provided
along machine direction 132 at a location which is between the
first and second webs 130 and 136, respectively, of stretchable
material. Substrate web 140 has laterally opposed longitudinally
extending side edge regions 142 and 144 thereof. A longitudinally
extending lateral side edge region 146 of the first web 130 of
stretchable material is attached to the first side edge region 142
of substrate web 140 to provide a first bonded region 148. A
longitudinally extending lateral side edge region 150 of the second
web 136 of stretchable material is attached to the second side edge
region 144 of substrate web 140 to provide a second bonded region
152. A first longitudinally extending web of stiffening material
154, such as a first web of spunbond nonwoven fabric or other
suitable material, can optionally be laid to overlap first bonded
region 148, and is operably connected to the first web of
stretchable material 130 and to substrate web 140. In particular,
the first web of stiffening material 154 can connect to side edge
region 146 of stretchable web 130 and to the first side edge region
142 of substrate web 140. A second longitudinally extending web of
stiffening material 156, such as a second web of spunbond nonwoven
fabric or other suitable material, can optionally be laid to
overlap second bonded region 152, and is operably connected to the
second web of stretchable material 136 and to substrate web 140. In
particular, stiffening web 156 can connect to side edge region 150
of the second stretchable web and to second side edge region 144 of
substrate web 140. Release tape web 182 is delivered and arranged
to place release surface 78 against the primary adhesive layer 54
on substrate web 140. Substrate web 140 is separated along a
longitudinally extending medial region thereof with a substantially
regularly undulating serpentine separation line 158 to provide an
opposed pair of composite subassemblies 160 and 162. The forming of
serpentine separation line 158 operably severs both substrate web
140 and release tape web 182 during the course of providing the
opposed pair of composite subassemblies 160 and 162. At least one
subassembly, and preferably both subassemblies, are divided along a
plurality of division lines 164 which extend substantially
laterally across each subassembly to provide a plurality of
combined panel-and-fastener components 166, as representatively
shown in FIGS. 12A and 12B.
The securing surface 188 of the release tape web can be employed to
anchor the subsequently formed individual release tape members to
suitable portions of the final article, such as a selected, inner
bodyside surface of diaper 20. As representatively shown in FIGS.
12C and 12D, for example, the release tape 74 can be anchored to a
selected surface region of the individual panel-and-fastener
component 166. Alternatively, the release tape 74 can be anchored
to a selected area of the bodyside surface of topsheet layer
24.
For example, a further aspect of the invention, representatively
shown in FIG. 13, generally corresponds to the configuration of the
invention shown in FIG. 12, except that the optional steps of
providing stiffening webs 154 and 156 are deleted. FIG. 13A
illustrates an alternative configuration of the invention which
employs a relatively narrower web of release tape material 182. In
the arrangement of FIG. 13A, the release tape web overlies the
adhesive layer 54, but does not overlap the elastomeric webs 130
and 136.
At least one subassembly 162, and preferably both subassemblies,
are divided along a plurality of division lines 164 which extend
substantially laterally across each subassembly to provide a
plurality of combined panel-and-fastener components 166, as
representatively shown in FIGS. 13B and 13C. Similar to the process
illustrated in FIG. 12, the configuration of the invention
illustrated in FIG. 13 can be arranged to anchor the release tape
74 can be anchored to a selected surface region of the individual
panel-and-fastener component 166, as representatively shown in
FIGS. 13D and 13E.
Alternatively, the release tape 74 can be anchored to a selected
area of the bodyside surface of topsheet layer 24 of the composite
web 180, as representatively shown in FIG. 14. The Figure
illustrates the configuration of fastening tab 44 after the tab has
been peeled from the release surface of the release tape 74, and
the user-bond adhesive on the tab has been exposed for use. In the
storage condition that would typically precede the arrangement
shown in FIG. 14, the adhesive bearing, user-bond surface of
fastening tab 44 is appropriately arranged such that it can be
releasably positioned and held against the release surface of
release tape 74. As a result, when side panel 90 is in its storage
configuration, the side panel is folded over upon itself to allow
for more efficient packaging.
Accordingly, a further aspect of the invention can include the
steps of securing at least one of said panel-and-fastener
components to each of two laterally opposed end regions 172 of the
appointed waistband section 174 of the article web 176 to provide
the composite article web 180; and inwardly folding the first and
second webs of elastomerically stretchable material 130 and 136 to
anchor the securing surface of the release tape material onto a
selected surface region of the composite article web.
With reference to FIG. 15, another aspect of the invention can
include the step of connecting the first longitudinally extending
web of stiffening material 154 is attached to a major facing
surface of substrate web 140 at a location which is proximate the
first side edge region 142 of the substrate web, and is laterally,
inwardly spaced from the first side edge region of the substrate
web. In addition, the second longitudinally extending web of
stiffening material 156 is attached to a major facing surface of
substrate web 140 at a location which is proximate the second side
edge region 144 of the substrate web 140, and is laterally,
inwardly spaced from the second side edge region of the substrate
web.
With reference to FIG. 16, another aspect of the invention can
include the step of connecting substrate web 140 between two side
panel webs, such as provided by first and second elastomeric webs
130 and 136. The first longitudinally extending web of stiffening
material 154 is attached to a major facing surface of elastomeric
web 130 at a location which is proximate the first bonded edge
region 148 of the elastomeric web 130, and is laterally, outwardly
spaced from the first side edge region 142 of the substrate web
140. In addition, the second longitudinally extending web of
stiffening material 156 is attached to a major facing surface of
elastomeric web 136 at a location which is proximate the second
bonded edge region 152 of elastomeric web 136, and is laterally,
outwardly spaced from the side edge region 144 of the substrate web
140. Accordingly, the process can be employed to form a fastener
system having a stress beam section 98 spaced a selected, discrete
distance from the edge of its associated fastener tab 44.
In the various configurations of the invention, the elastomerically
stretchable webs 130 and 136 can be composed of any of the
materials employed to construct the appointed elastomeric side
panels 90. Accordingly, the elastomeric webs can be composed of a
stretch-bonded-laminate (SBL) material, a neck-bonded-laminate
(NBL) material, an elastomeric film, an elastomeric foam material,
or the like. For example, suitable meltblown elastomeric fibrous
webs for forming side panels 90 are described in U.S. Pat. No.
4,663,220 issued May 5, 1987 to T. Wisneski et al., the disclosure
of which is hereby incorporated by reference. Examples of composite
fabrics comprising at least one layer of nonwoven textile fabric
secured to a fibrous elastic layer are described in European Patent
Application No. EP 0 110 010 published on Apr. 8, 1987 with the
inventors listed as J. Taylor et al., the disclosure of which is
hereby incorporated by reference. Examples of NBL materials are
described in U.S. Pat. No. 5,226,992 issued Jul. 13, 1993 to
Mormon, the disclosure of which is hereby incorporated by
reference.
Similarly, substrate web 140 can be composed of any one of the
materials suitable for providing fastener tab substrate 48.
Accordingly, the substrate web can be composed of a fabric material
or a suitable polymer film material, such as polypropylene,
polyethylene or other suitable polyolefin. The material comprising
substrate web 140 may be opaque, translucent or transparent, as
desired, and may include graphics thereon. Optionally, the material
may be tinted and/or textured, and may also be selectively
embossed. In particular aspects of the invention, substrate web 140
can be constructed of a substantially non-extensible and/or a
substantially non-elastomeric material to provide desired
benefits.
Release tape webs 182 and 184 can be composed of any of the
suitable materials desired for providing release tape 74.
Accordingly, the release tape webs can, for example, be composed of
a 3M KS-0080 release tape composed of a 3.5 mil thick polypropylene
film with a poly dimethylsiloxane release coating and an aliphatic
resin. Such release tapes are available from the 3M Company, St.
Paul, Minn. It should be readily appreciated that the various webs
employed in the method of the invention can be suitably attached to
each other employing conventional connecting means. Such connecting
means can include, for example, adhesive bonding, thermal bonding,
ultrasonic bonding, clips, staples, sewing, or the like, or
combinations thereof.
In the various aspects of the invention, the individual fasteners
44 and the individual panel-and-fastener components 166 can be
nested within the corresponding fastener tab and composite
subassemblies from which the fasteners and panel-and-fastener
components are formed. With respect to the individual fastener tabs
formed from subassemblies 194 and 196, for example, the fastener
tabs formed from subassembly 194 are substantially of equal size
and are approximately mirror images of the complementary fasteners
formed from subassembly 196. The fasteners tabs produced from
nested subassembly 194 are slightly offset from the fasteners
produced from nested subassembly 196 by a discrete distance along
the length dimension of substrate material 140. More particularly,
a nested fastener from subassembly 194 is offset from its opposed
counterpart fastener from subassembly 196 by approximately one-half
of the desired top-to-bottom span along of an individual tape
fastener 44 along the length dimension of the article. In the
illustrated embodiment, serpentine separation line 158 stops short
of the laterally outboard edges of the finger tab/release tape webs
182 and 184 along cross-direction 134. Optionally, the
cross-directional extent of serpentine cut 118 may substantially
coincide with the terminal outboard edge boundaries of the finger
tab web, or may extend beyond the outboard edge boundaries of the
finger tab material.
Having thus described the invention in rather full detail, it will
be readily apparent that various changes and modifications can be
made without departing from the spirit of the invention. All of
such changes and modifications are contemplated as being within the
scope of the invention, as defined by the subjoined claims.
* * * * *